Interior panel structure

ABSTRACT

The invention relates to an interior panel structure including first and second panels formed into an L-shaped panel structure and an L-shaped reinforcing member fixed to an outer corner portion of the L-shaped panel structure. The reinforcing member has a plurality of first through holes that are opposed to a minor face of the first panel. With this, it is possible to observe condition of the minor face of the first panel and remove major projections of the minor face. Thus, the interior panel structure is improved in external appearance.

BACKGROUND OF THE INVENTION

The present invention relates to an interior panel structure for forming inner walls of buildings and particularly to a connected structure of two interior panels (e.g., gypsum boards).

In recent years, it has been well known to use gypsum boards or the like, which are superior in workability and heat insulation, as building interior members.

Japanese Patent Publication JP-A-8-326183 discloses a method for connecting two wall panels together.

SUMMARY OF THE INVENTION

It is an object of the present invention to provide an interior panel structure, which is superior in external appearance.

According to the present invention, there is provided an interior panel structure, comprising:

-   -   a first panel having first and second major faces opposed to         each other and a minor face defined between the first and second         major faces;     -   a second panel having first and second major faces opposed to         each other and a minor face defined between the first and second         major faces, the minor face of the second panel being in         abutment with a corresponding end portion of the second major         face of the first panel such that the first and second panels         are substantially perpendicular to each other to form an         L-shaped panel structure and that the minor faces of the first         and second panels are adjacent to and substantially         perpendicular to each other; and     -   an L-shaped reinforcing member fixed to an outer corner portion         of the L-shaped panel structure, the reinforcing member having         first and second planar portions that are substantially         perpendicular to each other and an edge defined therebetween,         the first planar portion covering a corresponding end portion of         the first major surface of the first panel, the second planer         portion having an inner portion for covering the minor face of         the first panel and an outer portion for covering a         corresponding end portion of the first major face of the second         panel, the inner portion having a plurality of first through         holes that are arranged along and adjacent to the edge of the         reinforcing member, for observing condition of the minor face of         the first panel.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an exploded perspective view showing a first interior panel structure according to the first embodiment of the present invention;

FIG. 2 is a perspective view showing the first interior panel structure, in which the L-shaped reinforcing member is fixed to the outer corner portion of the L-shaped panel structure of the first and second panels;

FIG. 3 is a view similar to FIG. 1, but showing a second interior panel structure according to the second embodiment of the present invention; and

FIG. 4 is a view similar to FIG. 2, but showing the second interior panel structure.

DETAILED DESCRIPTION

With reference to FIGS. 1 and 2, the first interior panel structure according to the first embodiment of the present invention is described in detail in the following.

As is seen from FIG. 1, the first interior panel structure has first and second panels (gypsum boards) 11 and 12. Their side end portions 11 a and 12 a are joined together to forma an L-shaped panel structure.

Each of the first and second panels 11 and 12 may have a thickness of about 10 mm and a length of about 1.8 m to about 2.75 m in the vertical direction in FIG. 1 or 2.

The first panel 11 has first and second major faces opposed to each other and a minor face 11 b defined therebetween, and the second panel 12 has first and second major faces opposed to each other and a minor face 12 b defined therebetween.

According to need, the first panel 11 may be cut on site to have a suitable size and to expose the minor face 11 b. Due to cutting on site, it may be difficult to provide the minor face 11 b with a perfectly flat surface. In other words, the minor face 11 b may have major projections 18 and minor projections where major projections 18 have heights that are greater than those of minor projections. The boundary between the major and minor projections may be changed depending on, for example, the thickness of the first and second panels 11 and 12.

Such major projections 18 can easily be removed in the present invention, as described hereinafter in detail. In contrast, the removal of the minor projections is omitted, since they do not affect external appearance of the interior panel structure of the present invention by a special positioning of the first and second panels 11 and 12 relative to each other, as described hereinafter in detail.

The first panel 11 has thick cardboards 14 bonded to the first and second major faces of a gypsum board proper. Similarly, the second panel has thick cardboards 15 bonded to the first and second major faces of a gypsum board proper.

In the L-shaped panel structure of the first and second panels 11 and 12, a majority of the minor face 12 b of the second panel 12 is in abutment with a corresponding end portion of the second major face of the first panel 11 such that the first and second panels 11 and 12 are substantially perpendicular to each other and that the minor faces 11 b and 12 b of the first and second panels 11 and 12 are adjacent to each other and substantially perpendicular to each other.

The first interior panel structure has an L-shaped reinforcing member 13 that may be made of a synthetic resin and is substantially L-shaped in cross section. The reinforcing member 13 may be monolithically formed by extrusion to have an elongate shape. It may be cut on site to have a suitable length depending on the size of the first and second panels 11 and 12. The reinforcing member 13 is fixed to an outer corner surface of the L-shaped panel structure for reinforcing the corner of the L-shaped panel structure.

The reinforcing member 13 has an edge 13 a and first and second planar portions 13 c and 13 b that are substantially perpendicular to each other. As is seen from FIG. 2, the first planar portion 13 c covers a corresponding end portion of the first major surface of the first panel 11. The second planar portion 13 b has an inner portion for covering the minor face 11 b of the first panel 11 and an outer portion 21 for covering a corresponding end portion of the first major face of the second panel 12. The inner portion has a plurality of first through holes 20 that are arranged along and adjacent to the edge 13 a, for observing condition of the minor face 11 b of the first panel 11.

The reinforcing member 13 is fixed to the outer corner portion of the L-shaped panel structure of the first and second panels 11 and 12 through two double-faced adhesive tapes 16 and 17 bonded to inner surfaces of the outer portions of the first and second planar portions. The outer portion 21 of the second planar portion 13 b, which is defined from the outer edge of the first through holes 20 to the outer edge 13 d of the second planar portion 13 b, is a planar region for providing adhesion between the reinforcing member 13 and the L-shaped panel structure.

The outer portion 21 of the second planar portion 13 b has a width that can accommodate a relatively wide, double-faced, adhesive tape, and the first planar portion 13 c has a width that can accommodate such double-faced, adhesive tape. With this, it is possible to fix the reinforcing member 13 to the L-shaped panel structure with a sufficient strength. The first planar portion 13 c shown in FIG. 1 may be shortened to have a width that fitly accommodates a double-faced, adhesive tape.

The first through holes 20 are aligned along the edge 13 a. Adjacent through holes 20 are sufficiently close to each other to have a predetermined distance therebetween. Furthermore, each through hole may have a sufficient size (e.g., a diameter of about 10 mm) that allows a finding of the above-explained major projections 18, if any, formed on the minor face 11 b of the first panel 11 and an operation of a tool (e.g., cutter) against the minor face 11 b of the first panel 11 through the through holes 20. In other words, it is possible to easily remove such major projections 18 with the tool by inserting the tip of the tool into the corresponding through holes 20.

Furthermore, according to the present invention, the first panel 11 is positioned relative to the second panel 12 such that the minor face 11 b of the first panel 11 is spaced away from the first major face of the second panel 12 in a direction along the width of the minor face 12 b of the second panel 12 to have a distance L (see FIG. 1) and to have a space between the minor face 11 b of the first panel 11 and the inner portion of the second planar portion 13 b of the reinforcing member 13. The distance L is variable and may be set by a worker on site. It may be, for example, about 1 mm in case that each of the first and second panels 11 and 12 has a thickness of about 10 mm. In fact, the above-explained minor projections are defined as having heights from a reference place of the minor face 11 b, which are less than the distance L. Therefore, it is possible to say that the minor projections are absorbed by the distance L and thereby do not deform the reinforcing member 13. Thus, the minor projections are not removed in the present invention. As a result, it is possible to produce an interior panel structure that is superior in external appearance.

As is seen from FIG. 2, the reinforcing member 13 may be temporarily fixed to the L-shaped panel structure of the first and second panels 11 and 12. Under this condition, it is possible to find the major projections 18, which are not absorbed by the distance L, by observing the minor face 11 b of the first panel 11 through the first through holes 20 and then put marks on all of the major projections 18.

After that, it is possible to take the reinforcing member 13 from the L-shaped panel structure and then remove all of the major projections 18 by a cutter or the like. In other words, the major projections 18 can turn into minor projections by cutting with a cutter or the like. Then, it is possible to take cover papers from the double-faced adhesive papers 16 and 17 and then to fix the reinforcing member 13 to the L-shaped panel structure in a manner to bring the double-faced adhesive papers 16 and 17 into a pressing abutment with the first and second panels 11 and 12. Thus, it is possible to surely prevent deformation of the first and second planar portions 13 c and 13 b of the reinforcing member 13, thereby making the edge 13 a of the reinforcing member 13 straight. This improves the final product in external appearance.

Then, putty can be applied to various portions of the panel structure, such as an outer surface of the reinforcing member 13, a stepped portion defined between the outer edge 13 e or 13 d of the reinforcing member 13 and the first or second panel 11 or 12, and the space defined between the minor face 11 b of the first panel 11 and the inner portion of the second planar portion 13 b of the reinforcing member 13. After that, an outer face of the panel structure can be wrapped with an interior finish such as vinyl cloth (synthetic cloth).

As mentioned above, each of the first through holes 20 has a relatively large size that allows insertion of a tool (e.g., cutter). Thus, it becomes easy to put putty into the space through the first through holes 20 until filling the through holes 20 with putty. Therefore, the finish of the interior panel structure becomes remarkably good, and it becomes possible to obtain a good putty adhesion.

As an alternative to the above-mentioned preparation of the first interior panel structure with the temporary fixing of the reinforcing member, the first interior panel structure can be prepared, as follows.

Firstly, it is possible to take cover papers from the double-faced adhesive papers 16 and 17 and then fix the reinforcing member 13 to the L-shaped panel structure in a manner to bring the double-faced adhesive papers 16 and 17 into a pressing abutment with the first and second panels 11 and 12. Under this condition, the major projections 18 and burr of the cardboards 14, 15 can easily be found and removed by a cutter through the first through holes 20, since the first through holes 20 have a relatively large size and are continuously arranged to have a close distance between the two adjacent holes 20. This makes the operation of fixing the reinforcing member 13 simpler. Then, putty can be applied to various portions of the panel structure, as mentioned above.

It is optional to form slits on the inner surface of the inner portion of the second planar portion 13 b of the reinforcing member 13. Thus, the putty may intrude into the slits to improve the putty adhesion strength.

With reference to FIGS. 3 and 4, the second interior panel structure according to the second embodiment of the present invention is described in detail in the following. Since the second interior panel structure is the same as the above-explained first interior panel structure except the reinforcing member, parts and constructions of the second interior panel structure corresponding to those of the first interior panel structure are denoted by the same numerals and their explanations are omitted.

The reinforcing member 13 is additionally formed with second through holes 22 on the inner portion of the first planar portion 13 c. In fact, the first and second through holes 20 and 22 are symmetrically arranged about the edge 13 a. The first planar portion 13 c has an outer portion for accommodating thereon a double-faced adhesive tape 16.

By the provision of the first and second through holes 20 and 22, it becomes much easier to find and remove the major projections 18, as compared with the first interior panel structure.

Since the first and second through holes 20 and 22 are symmetrically arranged about the edge 13 a, the reinforcing member 13 may be upside down relative to the L-shaped panel structure of the first and second panels 11 and 12 in the preparation of the interior panel structure.

The present invention is not limited to the above-explained first and second embodiments. For example, the size of the first and second through holes 20 and 22 may be enlarged, depending on the tool used for removing the major projections 18 and burr of the cardboards 14. The position of the first and second through holes 20 and 22 may be changed.

The first and second panels 11 and 12 are not limited to gypsum boards. They may be selected from various ceramic boards (e.g., rock wool board) and noncombustible materials. The size of the first and second panels 11 and 12 is not particularly limited. It can freely be changed according to need.

As an alternative to the double-faced adhesive tapes 16 and 17, an adhesive may previously be applied to the first and second planar portions 13 c and 13 b of the reinforcing member 13 in order to fix the reinforcing member 13 to the L-shaped panel structure of the first and second panels 11 and 12. 

1. An interior panel structure, comprising: a first panel having first and second major faces opposed to each other and a minor face defined between the first and second major faces; a second panel having first and second major faces opposed to each other and a minor face defined between the first and second major faces, the minor face of the second panel being in abutment with a corresponding end portion of the second major face of the first panel such that the first and second panels are substantially perpendicular to each other to form an L-shaped panel structure and that the minor faces of the first and second panels are adjacent to and substantially perpendicular to each other; and an L-shaped reinforcing member fixed to an outer corner portion of the L-shaped panel structure, the reinforcing member having first and second planar portions that are substantially perpendicular to each other and an edge defined therebetween, the first planar portion covering a corresponding end portion of the first major surface of the first panel, the second planer portion having an inner portion for covering the minor face of the first panel and an outer portion for covering a corresponding end portion of the first major face of the second panel, the inner portion having a plurality of first through holes that are arranged along and adjacent to the edge of the reinforcing member, for observing condition of the minor face of the first panel.
 2. An interior panel structure according to claim 1, wherein the first through holes are arranged in a single row.
 3. An interior panel structure according to claim 1, wherein the first planar portion of the reinforcing member has an inner portion formed with a plurality of second through holes arranged along and adjacent to the edge of the reinforcing member.
 4. An interior panel structure according to claim 3, wherein the first and second through holes of the reinforcing member are symmetrically arranged about the edge of the reinforcing member.
 5. An interior panel structure according to claim 1, wherein the first planar portion of the reinforcing member is bonded to the first panel, and the outer portion of the second planar portion of the reinforcing member is bonded to the second panel.
 6. An interior panel structure according to claim 1, wherein each of the first through holes of the reinforcing member has a size that allows an operation of a tool against the minor face of the first panel through the first through hole.
 7. An interior panel structure according to claim 3, wherein each of the second through holes of the reinforcing member has a size that allows an operation of a tool against the minor face of the first panel through the first through hole.
 8. An interior panel structure according to claim 1, wherein each of the first through holes of the reinforcing member is circular in shape.
 9. An interior panel structure according to claim 3, wherein each of the second through holes of the reinforcing member is circular in shape.
 10. An interior panel structure according to claim 1, wherein the first panel is positioned relative to the second panel such that the minor face of the first panel is spaced away from the first major face of the second panel in a direction along the minor face of the second panel to have a space between the minor face of the first panel and the inner portion of the second planar portion of the reinforcing member.
 11. An interior panel structure according to claim 10, wherein the space is filled with putty.
 12. An interior panel structure according to claim 1, wherein the first planar portion of the reinforcing member is bonded to the first panel by a double-faced adhesive tape, and wherein the outer portion of the second planar portion of the reinforcing member is bonded to the second panel by a double-faced adhesive tape.
 13. An interior panel structure according to claim 1, wherein each of the first and second panels is a gypsum board. 